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Mechanical Properties and Microstructural Characteristics of Al–Mg Alloy Cylindrical Component Manufactured by Wire Arc Additive Manufacturing Process

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Abstract

Wire arc additive manufacturing (WAAM) is a viable alternative to traditional machining to manufacture large parts with complicated geometry, as well as customized quantity components, using cost-effective production resources. Al–Mg (Aluminum–Magnesium) alloy cylindrical component was manufactured using a wire arc additive manufacturing (WAAM) technique based on gas metal arc welding (GMAW) process. The porosity, microstructural characteristics and mechanical properties of the lower and upper zones of wire arc additively manufactured cylindrical component are studied. The yield strength, ultimate tensile strength and % elongation were found to be 128 ± 7 MPa, 219 ± 4.5 MPa and 38 ± 2.7% in the lower and upper zones, respectively. The hardness and impact toughness were found to be 69.94 ± 2.76 (Hv0.5) and 10 ± 1 J in the lower and upper zones, respectively. Grain size differences in the inner-layer and inter-layer regions of the cylindrical component were identified along the building direction based on microstructural analysis. The fractographs showed typical dimple fracture features in all samples. From the results of this study, it is evident that the cylindrical component made using WAAM-GMAW technique outperformed traditional casting alloys such as 5356.

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Acknowledgements

The first author is grateful for the financial assistance provided by the Department of Science and Technology (DST), Ministry of Science and Technology, Government of India, New Delhi, through the PURSE-Phase-2 Fellowship scheme. The authors express their gratitude to M/s. Fronius India Pvt.Limited, Chennai, for their technical assistance.

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  1. Department of Manufacturing Engineering, Centre for Materials Joining and Research (CEMAJOR), Annamalai University, Annamalainagar – (P.O), Tamilnadu (State), 608002, India

    Bellamkonda Prasanna Nagasai, Sudersanan Malarvizhi & Visvalingam Balasubramanian

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  1. Bellamkonda Prasanna Nagasai
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  2. Sudersanan Malarvizhi
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  3. Visvalingam Balasubramanian
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Correspondence to Bellamkonda Prasanna Nagasai.

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Nagasai, B.P., Malarvizhi, S. & Balasubramanian, V. Mechanical Properties and Microstructural Characteristics of Al–Mg Alloy Cylindrical Component Manufactured by Wire Arc Additive Manufacturing Process. Metallogr. Microstruct. Anal. 11, 199–211 (2022). https://doi.org/10.1007/s13632-022-00841-2

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